Sock-lined footwear and associated manufacturing method

ABSTRACT

The present disclosure concerns a sock-lined footwear upper defining a foot-receiving cavity and comprising a sock having an outer surface and an inner surface at least partially delimiting the foot-receiving cavity and comprising a heel counter area; an outer layer covering at least partially the outer surface of the sock; and a heel pad at least partially secured to the inner surface of the sock in the heel counter area thereof. The present disclosure also concerns such a heel pad, an item of sock-lined footwear comprising such an upper and a method for manufacturing such an item of sock-lined footwear.

PRIOR APPLICATION

The present application claims priority from U.S. provisional patentapplication No. 62/829,224, filed on Apr. 4, 2019, and entitled“Sock-lined footwear and associated manufacturing method”, thedisclosure of which being hereby incorporated by reference in itsentirety.

TECHNICAL FIELD

The technical field relates to footwear and, more particularly, tosock-lined footwear, and to associated manufacturing methods.

BACKGROUND

Sock-lined footwear, such as boots, is used for instance in outdoorrecreational activities as well as in a number of industrial andprofessional uses. One type of sock-lined footwear includes an innerlayer—or inner sock—fully covered by an outer layer of waterproofmaterial, such as vulcanized rubber or polyurethane. This double-layeredconstruction provides a light-weight boot that fits the foot of thewearer.

It has been noticed that when the wearer walks with their item ofsock-lined footwear, their foot tends to move out of a foot-receivingcavity of the item of sock-lined footwear. This phenomenon is sometimescalled heel-flopping. Such a displacement of the foot within thefoot-receiving cavity, by being repeated, can injure the wearer, forinstance by irritating the skin of the wearer. Moreover, the wearermight also have to regularly reposition their foot in the foot-receivingcavity, which is not satisfactory. In view of the above, there is a needfor sock-lined footwear which would be able to overcome or at leastminimize some of the above-discussed prior art concerns.

BRIEF SUMMARY

It is therefore an aim of the present invention to address theabove-mentioned issues.

According to a general aspect, there is provided a sock-lined footwearupper defining a foot-receiving cavity and comprising: a sock having anouter surface and an inner surface at least partially delimiting thefoot-receiving cavity and comprising a heel counter area; an outer layercovering at least partially the outer surface of the sock; and a heelpad at least partially secured to the inner surface of the sock in theheel counter area thereof.

According to another general aspect, there is provided a heel pad for asock-lined footwear upper comprising an inner sock having an innersurface at least partially delimiting a foot-receiving cavity andcomprising a heel counter area, the heel pad having a length and aheight and comprising: an outer surface securable to the inner surfaceof the inner sock in the heel counter area thereof; an opposed innersurface; and at least one heel-abutting portion protruding forwardly andcreating at least one protrusion on the inner surface, the at least oneheel-abutting portion extending along at least a portion of the length,the heel-abutting portion being shaped and dimensioned to extend atleast partially above a heel of a user's foot at least partially engagedinto the foot-receiving cavity when the heel pad is at least partiallysecured to the inner sock.

According to another general aspect, there is provided an item ofsock-lined footwear comprising: an outsole having an inner surface andan outer surface; and a sock-lined footwear upper according to thepresent disclosure, the sock-lined footwear upper extending from theoutsole, the heel pad being adjacent to the outsole.

According to another general aspect, there is provided a method formanufacturing an item of sock-lined footwear, the method comprising:providing a heel pad and a sock having an outer surface and an innersurface comprising a heel counter area; securing the heel pad to theinner surface of the sock, in the heel counter area thereof; providing afootwear last having an outer surface with a heel pad-receiving recessformed therein; positioning the sock over the footwear last with theheel pad at least partially received in the heel pad-receiving recess;covering at least partially the outer surface of the sock with avulcanizable material; and forming at least partially an upper of theitem of sock-lined footwear with said vulcanizable material.

According to another general aspect, there is provided a method formanufacturing a sock-lined footwear comprising securing a heel pad to aninner surface of a sock, in a heel counter area, providing a last havingan outer surface with a heel pad recess defined therein, positioning thesock over the last with the heel pad being received in the heel padrecess; covering an outer surface of the sock with a vulcanizablematerial and forming an upper of the sock-lined footwear with saidvulcanizable material.

According to another general aspect, there is provided a sock-linedfootwear upper defining a foot-receiving cavity and comprising a sockhaving an outer surface and an inner surface comprising a heel counterarea, an outer layer at least partially bonded to the outer surface ofthe sock, and a heel pad secured to the inner surface of the sock in theheel counter area.

According to yet another general aspect, there is provided sock-linedfootwear comprising an outsole having an inner surface and an outersurface; and an upper according to the present disclosure, the upperextending from the outsole.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional side view of an item of sock-lined footwearhaving a heel pad in accordance with one embodiment;

FIG. 2 is a front elevation view of the heel pad illustrated in FIG. 1;

FIG. 3 is a right-side elevation view of the heel pad of FIG. 2;

FIG. 4 is a sectional view of the heel pad of FIG. 2 taken alongcross-section lines A-A;

FIG. 5 is a front elevation view of a heel pad in accordance withanother embodiment;

FIG. 6 is a sectional view of the heel pad of FIG. 5 taken alongcross-section lines B-B;

FIG. 7 is a sectional view of the heel pad of FIG. 5 taken alongcross-section lines C-C;

FIG. 8 is a front elevation view of a heel pad in accordance withanother embodiment;

FIGS. 9 and 10 are schematic drawings of a mold assembly for forming theheel pad of FIG. 2, the mold assembly being configured respectively in aclosed configuration and in an open configuration;

FIG. 11 is a schematic drawing of a footwear last for forming thesock-lined footwear of FIG. 1; and

FIG. 12 is a flowchart representing steps of a method for manufacturingan item of sock-lined footwear, in accordance with an embodiment.

DETAILED DESCRIPTION

In the following description, the same numerical references refer tosimilar elements. Furthermore, for the sake of simplicity and clarity,namely so as to not unduly burden the figures with several referencesnumbers, not all figures contain references to all the components andfeatures, and references to some components and features may be found inonly one figure, and components and features of the present disclosurewhich are illustrated in other figures can be easily inferred therefrom.The embodiments, geometrical configurations, materials mentioned and/ordimensions shown in the figures are optional and are given forexemplification purposes only.

Moreover, it will be appreciated that positional descriptions such as“above”, “below”, “forward”, “rearward”, “left”, “right” and the likeshould, unless otherwise indicated, be taken in the context of thefigures and correspond to the position and orientation of the sock-linedfootwear and corresponding parts when being worn by a user, with the“front” corresponding to a position closer to a toe portion of an itemof sock-lined footwear and the “back” corresponding to a position closerto a heel portion of the item of sock-lined footwear. Positionaldescriptions should not be considered limiting.

To provide a more concise description, some of the quantitativeexpressions given herein may be qualified with the term “about”. It isunderstood that whether the term “about” is used explicitly or not,every quantity given herein is meant to refer to an actual given value,and it is also meant to refer to the approximation to such given valuethat would reasonably be inferred based on the ordinary skill in theart, including approximations due to the experimental and/or measurementconditions for such given value.

It is to be understood that the phraseology and terminology employedherein is not to be construed as limiting and are for descriptivepurpose only. The principles and uses of the teachings of the presentdisclosure may be better understood with reference to the accompanyingdescription, figures and examples. It is to be understood that where theclaims or specification refer to “a” or “an” element, such reference isnot be construed that there is only one of that element. It is to beunderstood that where the specification states that a component,feature, structure, or characteristic “may”, “might”, “can” or “could”be included, that particular component, feature, structure, orcharacteristic is not required to be included.

Methods of the present invention may be implemented by performing orcompleting manually, automatically, or a combination thereof, selectedsteps or tasks. The term “method” may refer to manners, means,techniques and procedures for accomplishing a given task including, butnot limited to, those manners, means, techniques and procedures eitherknown to, or readily developed from known manners, means, techniques andprocedures by practitioners of the art to which the invention belongs.Meanings of technical and scientific terms used herein are to becommonly understood as by one of ordinary skill in the art to which theinvention belongs, unless otherwise defined.

The present invention may be implemented in the testing or practice withmethods and materials equivalent or similar to those described herein.

Sock-Lined Footwear Structure

Referring now to the drawings, and more particularly to FIG. 1, there isshown an item of sock-lined footwear 100 (or double-layered compositefootwear 100), in accordance with one embodiment. The item of sock-linedfootwear 100 includes an outsole 102 and an upper 104 (or sock-linedfootwear upper 104 or double-layered composite footwear upper 104)extending upwardly—substantially vertically, in the embodimentshown—from the outsole 102 and, in some embodiments, secured to theoutsole 102. The upper 104 comprises an outer layer 120 (or waterprooflayer 120) extending upwardly from the outsole 102.

In the embodiment shown, the upper 104 includes a curved sidewall 106which defines, with the outsole 102, a foot-receiving cavity 108 sizedand shaped to receive at least partially a foot of a wearer. Thefoot-receiving cavity 108 extends above the outsole 102. It is to benoted that in the following description, unless otherwise stated, theterms “inner” and “outer” should be understood relatively to thefoot-receiving cavity 108.

The outsole 102 includes an inner (top) surface 110 (or foot-facingsurface 110) which faces upwardly towards the upper 104 and into thefoot-receiving cavity 108 and an outer (bottom) surface 112 (orground-facing surface 112), opposite the inner surface 110, that isdesigned to contact, either directly or indirectly, a ground when theitem of sock-lined footwear 100 is worn. In the illustrated embodiment,the item of sock-lined footwear 100 is a boot so that the upper 104 isdimensioned to cover an ankle and at least a portion of a shin of thewearer.

In the embodiment shown, the item of sock-lined footwear 100 furthercomprises a sock 114 (or footwear inner layer or inner sock) having anouter surface 116 (or waterproof layer-facing surface) and an opposedinner surface 118 (foot-facing surface). The sock 114 is inserted in thefoot-receiving cavity 108, defined by the outer layer 120 of the upper104 and the outsole 102, and is superposed to the inner surfaces of theouter layer 120 and the outsole 102 to at least partially line same. Theouter layer 120 (and more particularly an inner surface thereof) of theupper 104 is at least partially bonded—for instance molded or vulcanizedor secured by any other suitable mechanical fasteners—onto the outersurface 116 of the sock 114.

The item of sock-lined footwear 100 further comprises a heel pad 122secured to the inner surface 118 of the inner sock 114, adjacent to (orin the vicinity of) the outsole 102 (of a rear portion orheel-supporting portion thereof, in the embodiment shown) when the sock114 is inserted in the foot receiving cavity 108.

In the embodiment shown, the inner sock 114 is shaped and sized toreceive at least partially the wearers foot and to extend upwardly overthe ankle and cover at least a portion of the wearer's shin.

The inner sock 114 can be at least partially made of a fabric material,such as nylon, cotton, canvas, fleece, insulation, wool, mesh, felt orother selected materials.

The inner surface 118 of the sock 114 comprises a heel counter area 124configured to face a heel of the wearer when the foot of the wearer isreceived in the foot receiving cavity 108, and a sole area 125,configured to face a sole of the foot of the wearer.

The outer layer 120 of the upper 104 (in particular at least a portionof the inner surface thereof) being bonded to—for instance molded orvulcanized onto—the outer surface 116 of the sock 114, it is understoodthat the sock 114 cannot be removed from the foot receiving cavity 108of the upper 104 (i.e. the sock 114 is irremovably engaged with theouter layer 120, i.e. the sock 114 cannot be separated from the outerlayer 120 without damaging at least partially at least one of the sock114 and the outer layer 120). Still in the illustrated embodiment, theouter layer 120 of the upper 104 of the item of sock-lined footwear 100is at least partially manufactured from a moldable material such aspolyurethane, rubber or any other moldable material which a skilledaddressee would consider to be appropriate. It is understood that themoldable material from which the outer layer 120 is at least partiallymanufactured is chosen to be lightweight, durable, and to haveinsulative properties.

Heel Pad

In the embodiment shown, the heel pad 122 is secured to the innersurface 118 of the sock 114, for instance in the heel counter area 124thereof.

As represented in particular in FIGS. 2 to 4, the heel pad 122 has aninner surface 130 (or foot-facing surface 130) and an opposed outersurface 132 (or inner sock-facing surface 132) superposable to the innersurface 118 of the sock 114. In the embodiment shown, the heel pad 122is sewed, for instance along at least a portion of a peripheral border134 thereof (or along at least a portion of a periphery thereof), to theinner sock 114. Other embodiments could be conceived in which the heelpad 122 would be glued to the inner surface 118 of the sock 114,stitched or secured by any other suitable mechanical fasteners to thesock 114.

As represented for instance in FIGS. 3 and 4, the heel pad 122 comprisesan inner layer 131 defining the inner surface 130, an outer layer 133defining the outer surface 132, and a resilient material layer 135—suchas latex or any other resilient material—sandwiched between the innerlayer 131 and the outer layer 133. For instance, in the embodimentshown, at least one of the inner and outer layers 131, 133 comprises alayer of tissue, such as jersey knit.

In the embodiment shown, the heel pad 122 has a substantiallysemi-circular shape so that the peripheral border 134 comprises asubstantially straight (or horizontal) peripheral edge 136 (orsole-facing edge 136) defining a diameter d1 of the heel pad 122, and anarcuate peripheral edge 138 extending above the substantially straightperipheral edge 136, when the heel pad 122 extends in a substantiallyvertical plane. In some embodiments, the first diameter d1(substantially corresponding to a substantially horizontal length of theheel pad 122) is comprised between about 30 mm and about 220 mm. In someother embodiments, the first diameter d1 is comprised between about 50mm and about 170 mm. In some other embodiments, the first diameter d1 iscomprised between about 70 mm and about 150 mm. In some otherembodiments, the first diameter d1 is comprised between about 90 mm andabout 130 mm. In yet some other embodiments, the first diameter d1 iscomprised between about 100 mm and about 120 mm.

The heel pad 122 defines a height h1, considered substantiallycentrally, and substantially perpendicular to the horizontal (orstraight) peripheral edge 136 (substantially vertically in theembodiment shown). In some embodiments, the height h1 is comprisedbetween about 7 mm and about 90 mm. In some other embodiments, theheight h1 is comprised between about 15 mm and about 60 mm. In someother embodiments, the height h1 is comprised between about 25 mm andabout 50 mm. In yet some other embodiments, the height h1 is comprisedbetween about 30 mm and about 40 mm.

The substantially straight peripheral edge 136 of the heel pad 122extends proximate the sole area 125 of the inner surface 118 of the sock114. In the embodiment shown, the straight peripheral edge 136 issecured to, or in the vicinity of, the sole area 125 of the innersurface 118 of the sock 114. The arcuate peripheral edge 138 is arrangedin (for instance secured to) the heel counter area 124 of the innersurface 118 of the sock 114.

In the embodiment shown, the heel pad 122 further comprises one or moreheel-abutting portions, for instance one or more elongated cushioningpads 140 protruding inwardly, i.e. the cushioning pads defineprotrusions on the inner surface 130, and extending along at least aportion of the length (substantially corresponding to the diameter d1,in the embodiment shown) of the heel pad 122. As detailed below, theheel-abutting portions are shaped and dimensioned to extend at leastpartially above a heel of the wearer when the wearer's foot is at leastpartially engaged in the foot-receiving cavity 108 and to at leastpartially circumscribe same upwardly.

In the embodiment shown, as represented in FIG. 2, two elongatedcushioning pads 140 are formed or provided in an upper portion 142 ofthe heel pad 122, near an upper part of the arcuate peripheral edge 138of the peripheral border 134. The two elongated cushioning pads 140 areformed symmetrically relative to an axis X1 extending substantiallyvertically (or centrally). In the embodiment shown, the axis X1 definesan axis of symmetry of the heel pad 122.

In the embodiment shown, the two elongated cushioning pads 140 definetogether a convexity towards an apex 143 of the heel pad 122. In otherwords, in the embodiment shown, the elongated cushioning pads 140 atleast partially substantially follow the arcuate peripheral edge 138 ofthe peripheral border 134.

In the embodiment shown, each of the elongated cushioning pads 140 issubstantially rectangular in shape and defines an approximate length 11and an approximate width w1. In the embodiment shown, the length 11 issubstantially inclined with regards to a horizontal direction. Forinstance, the length 11 defines a pad inclination angle α1 comprisedbetween about 5 degrees and about 80 degrees. In some embodiments, thepad inclination angle α1 is comprised between about 10 degrees and about60 degrees. In some embodiments, the pad inclination angle α1 iscomprised between about 20 degrees and about 50 degrees. In yet someother embodiments, the pad inclination angle α1 is comprised betweenabout 30 degrees and about 40 degrees.

In some embodiments, the length 11 of the elongated cushioning pad 140is comprised between about 15 mm and about 60 mm. In some otherembodiments, the length 11 is comprised between about 25 mm and about 50mm. In yet some other embodiments, the length 11 is comprised betweenabout 30 mm and about 40 mm.

In some embodiments, the width w1 of the elongated cushioning pad 140 iscomprised between about 15 mm and about 60 mm. In some otherembodiments, the width w1 is comprised between about 25 mm and about 50mm. In yet some other embodiments, the width w1 is comprised betweenabout 30 mm and about 40 mm.

In the embodiment shown, as represented in FIG. 3, at least a portion ofa peripheral border of the elongated pads 140 is substantially rounded(i.e. defines a convexity towards the foot-receiving cavity 108) inorder to limit the risk of injuring the heel of the wearer when abuttingthere against.

In the embodiment shown, the heel pad 122 also comprises one or moredepressions formed in the inner surface 130 of the heel pad 122. Forinstance, the heel pad 122 comprises a central depression 144, forinstance substantially circular in shape, formed in a lower part 146 ofthe heel pad 122, and further comprises an elongated depression 148extending along at least a portion of the lower part 146 of the heel pad122. In the embodiment shown, the elongated depression 148 extends atleast partially below the elongated cushioning pads 140, and at leastpartially intersects the central depression 144. The depressions 144,148 are shaped and dimensioned to provide space to the heel of thewearer, so as to limit the risk of heel friction against the heel pad122, more particularly against the inner surface 130 thereof, when theitem of sock-lined footwear 100 is worn. In the non-limitativeembodiment shown, the elongated depression 148 extends from one side tothe opposite side of the arcuate peripheral edge 138 of the peripheralborder 134.

In some embodiments, the central depression 144 has a diameter d2comprised between about 10 mm and about 50 mm. In some otherembodiments, the diameter d2 is comprised between about 20 mm and about40 mm. In yet some other embodiments, the diameter d2 is about 30 mm.

In the embodiment shown, the central depression 144 is spaced apart fromthe lower peripheral edge 136 (or substantially horizontal or straightperipheral edge 136, in the embodiment shown). In some embodiments, thecentral depression 144 is spaced apart from the lower peripheral edge136 from a distance d4 (considered with respect to a lower portion of aperipheral border of the central depression 144) comprised between about2 mm and about 30 mm. In some other embodiments, the distance d4 betweenthe lower (or straight) peripheral edge 136 and the central depression144 (i.e. a lower end thereof) is comprised between about 5 mm and about20 mm. In some other embodiments, the distance d4 between the straightperipheral edge 136 and the central depression 144 is comprised betweenabout 10 mm and about 15 mm.

The elongated depression 148 extends between an upper edge 149 and alower edge 151. For instance, at least one of the upper and lower edges149, 151 are substantially curved-shaped along at least a portion of thelength (corresponding to the diameter d1 in the embodiment shown inwhich the heel pad 122 has a substantially semi-circular shape) of theheel pad 122. For instance, the upper and lower edges 149, 151 arenon-linear and substantially parallel to each other. As represented inFIG. 2, a distance d3 between the upper edge 149 and the straightperipheral edge 136 (or lower portion 136) of the peripheral border 134of the heel pad 122 varies along the length of the heel pad 122. In someembodiments, the distance d3 at a central portion of the heel pad 122(i.e. in a section in which the central depression 144 is formed in theembodiment shown) is comprised between about 30 mm and about 60 mm. Insome embodiments, the distance d3 is comprised between about 40 mm andabout 50 mm. In some other embodiments, the distance d3 at the centralportion of the heel pad 122 is about 45 mm.

In the embodiment shown, the elongated depression 148 extendssymmetrically on each side of the substantially vertical axis X1.

In the embodiment shown, a distance between the upper edge 149 of theelongated depression 148 and the lower edge 136 (or straight peripheraledge 136) of the peripheral border 134 (forming a sole-facing edgevaries along the length (i.e. along the diameter d1 in the embodimentshown) of the heel pad 122. In the embodiment shown, the distancebetween the upper edge 149 and the straight peripheral edge 136 reachesa maximum corresponding to the distance d3 at the central portion. Insome embodiments, a distance d5 between the upper edge 149 and thestraight peripheral edge 136 proximate the arcuate peripheral edge 138of the peripheral border 134 is comprised between about 10 mm and about40 mm. In some other embodiments, the distance d5 in the vicinity of thearcuate peripheral edge 138 of the peripheral border 134 is comprisedbetween about 20 mm and about 30 mm. In some other embodiments, thedistance d3 proximate the arcuate peripheral edge 138 is about 25 mm. Insome embodiments, the distance between the upper edge 149 and thestraight peripheral edge 136 reaches a minimum between the centralportion and the vicinity of the arcuate peripheral edge 138 of theperipheral border 134.

As represented in FIGS. 3 and 4, the heel pad 122 thus presents avariable thickness along at least one of a height and the diameter d1(or length) of the heel pad 122. In other words, the thickness of theheel pad 122 varies on a surface area thereof. In the embodiment shown,the heel pad 122 is dividable, considered along a vertical directionthereof, into a heel-bordering portion 162 (comprising at leastpartially the upper portion 142 of the heel pad 122), a middle portion164 and a sole-adjacent portion 166 (comprising the lower part 146 ofthe heel pad 122). The middle portion 164 thus extends between theheel-bordering portion 162 and the sole-adjacent portion 166.

In the portions of the heel pad 122 distinct from the portionscomprising the cushioning pads 140 and the portions in which thedepressions 144, 148 are formed, for instance at least partially in themiddle portion 164, a first thickness t1 is comprised between about 1 mmand about 8 mm. In some other embodiments, the first thickness t1 iscomprised between about 2 mm and about 6 mm. In some other embodiments,the first thickness t1 of the heel pad 122 is comprised between about 3mm and about 5 mm. In yet some other embodiments, the first thickness t1is about 4 mm.

The heel pad 122 presents a second thickness t2 in an area comprisingthe cushioning pads 140, corresponding to a thickness of theheel-bordering portion 162. In some embodiments, the second thickness t2is comprised between about 5 mm and about 15 mm. In some embodiments,the second thickness t2 (i.e. the thickness of the heel-borderingportion 162) is comprised between about 7 mm and about 12 mm. In someembodiments, the second thickness t2 is comprised between about 8 mm andabout 11 mm. In yet some other embodiments, the second thickness t2 isabout 9.5 mm.

The heel pad 122 presents a third thickness t3 in the lower part 146thereof in which the elongated depression 148 is formed. In someembodiments, the third thickness t3 (i.e. the thickness of thesole-adjacent portion 166) is comprised between about 0.5 mm and about 5mm. In some other embodiments, the third thickness t3 is comprisedbetween 1 mm and about 4 mm. In some other embodiments, the thirdthickness t3 is comprised between about 2 mm and about 3 mm. In yet someother embodiments, the third thickness t3 is about 2.5 mm.

In other words, in the embodiment shown, the thickness t2 of theheel-bordering portion 162 is greater than the thickness t1 of themiddle portion 164. Moreover, in the embodiment shown, the thickness t3of the sole-adjacent portion 166 is smaller than the thickness t1 of themiddle portion 164 (and thus smaller than the thickness t2 of theheel-bordering portion 162).

In the embodiment show, as represented in FIG. 4, the heel pad 122presents a fourth thickness t4 in the region of the sole-adjacentportion 166 in which the central depression 144 is formed. In someembodiments, the fourth thickness t4 is smaller than about 2 mm. In someother embodiments, the fourth thickness t4 is smaller than about 1 mm.In yet some other embodiments, the fourth thickness t4 is about 0.5 mm.

In the embodiment shown, as represented in FIGS. 3 and 4, a thickness ofan area of the heel-bordering portion 162 which does not comprise thecushioning pads 140 and a thickness of an area of the sole-adjacentportion 166 in which no depressions are formed substantially correspondto the first thickness t1 of the heel pad (i.e. to the thickness t1 ofthe middle portion 164).

As represented in FIG. 4, the central depression 144 has an increasingdepth toward a depression center 147 thereof. In other words, thecentral depression 144 defines a concavity. As represented in FIG. 4, inthe embodiment wherein the central depression 144 at least partiallyintersects the elongated depression 148, and considered downwardly alongthe height h1 (i.e. towards the lower portion 136), the thickness of theheel pad 122 firstly decreases at the upper edge 149 of the elongateddepression 148, then increases at an upper peripheral border 145 of thecentral depression 144, then decreases toward the depression center 147,then increases toward a lower peripheral border 141 of the centraldepression 144. In the embodiment shown, the thickness of the heel pad122 at the lower peripheral border 141 is substantially equal to thefirst thickness t1 of the middle portion 164.

As mentioned above, the heel pad 122, and more particularly theelongated cushioning pads 140, are dimensioned and arranged to cooperatewith the heel of the wearer of the item of sock-lined footwear 100, soas to prevent, or at least reduce, a flopping of the item of sock-linedfootwear 100 when the wearer walks.

In some embodiments, the inner surface 130 of the heel pad 122 isdirectly in contact with the heel of the wearer, or with a sock worn bythe wearer. In some other embodiments, the item of sock-lined footwear100 further comprises an inner shoe (not represented) removablypositioned in the foot-receiving cavity 108 of the item of sock-linedfootwear 100. The inner surface 130 of the heel pad 122 is thus incontact with the removable inner shoe, to prevent, or at least reduce,the flopping of the removable inner shoe in the foot-receiving cavity108 when the wearer walks. In other words, the inner shoe forms anadditional layer between the foot of the user when received in thefoot-receiving cavity 108 and the sock 114.

Moreover, since the heel pad 122 is secured to the inner surface 118 ofthe sock 114, it cannot be displaced in the foot-receiving cavity 108 orremoved out of the foot-receiving cavity 108. Thereby, the heel-abuttingportions comprising the elongated cushioning pads 140, which aredesigned to form an abutment against a portion of the heel of thewearer, to limit or prevent a vertical movement of the heel in thefoot-receiving cavity 108 when the wearer walks, remain substantially atthe same location within the foot-receiving cavity 108.

It is appreciated that the shape and the configuration of the heel pad122, as well as the shape and the configurations of its peripheralborder 134, the shape, the number and the configuration of itsheel-abutting portions comprising the cushioning pads 140, and itsdepressions 144, 148 can vary from the embodiment shown.

For instance, a heel pad having a substantially triangular or squareshape could easily be conceived and/or having one single cushioning padand/or more than two elongated cushioning pads and/or more or less thana central depression and an elongated depression. Furthermore, the shapeand the configuration of the cushioning pads can vary from theembodiment shown. Moreover, the shape, the configuration and thelocation of central depression and the elongated depression can varyfrom the embodiment shown.

For instance, as represented in FIGS. 5 to 7, it could be conceived aheel pad 1122 with an elongated depression 1148 and a central depression1144 (substantially circular, in the embodiment shown), formed in aninner surface 1130 thereof, wherein the central depression 1144 and theelongated depression 1148, at the portion of the heel pad 1122 where theelongated depression 1148 and the central depression 1144 intersect,form together a continuously increasing depth towards a center 1147 ofthe central depression 1144, i.e. the heel pad 1122 decreases inthickness.

Moreover, as represented in FIGS. 6 and 7, in the embodiment shown, theheel pad 1122 comprises two substantially rectangular elongatedcushioning pads 1140 protruding inwardly, i.e. the cushioning pads 1140define protrusions on the inner surface 1130. In the embodiment shown,at least in a heel-bordering portion 1162 of the heel pad 1122, the heelpad 1122 is formed of at least two layers: a cushioning layer 1137forming at least partially the elongated cushioning pads 1140, and acore layer 1135, for instance at least partially made of a resilientmaterial, such as latex or any other resilient material, the two layersbeing secured (i.e. bonded) to each other. The cushioning layer 1137might have properties (such as resilient and/or softness properties)different from the properties of the core layer 1135. In the embodimentshown, the core layer 1135 also forms at least partially a middleportion 1164 and a sole-adjacent portion 1166 of the heel pad 1122. Alower portion 1139 of the sole-adjacent portion 1166 could, forinstance, be formed in a different material. As represented in FIG. 5,the portion of the heel pad 1122 in which the central depression 1144 isformed could be formed in at least two distinct materials, for instancea first material forming at least partially a central area 1150 of thecentral depression 1144, and a second material forming at leastpartially a peripheral area 1152 of the central depression 1144.

As shown in FIG. 8, it could also be conceived a heel pad 2122 with nodepressions formed in an inner surface 2130 thereof. In the embodimentshown, the heel pad 2122 also comprises two elongated cushioning pads2140 formed or provided symmetrically relative to an axis X1 extendingsubstantially vertically and centrally. It could also be conceived aheel pad that would comprise a single elongated cushioning pad withsections thereof that would extend on each side of the central axis X1.

Sock-Lined Footwear Manufacturing Method

The present disclosure also relates to a method 200 for manufacturing anitem of sock-lined footwear 100 comprising a heel pad 122 in accordancewith the present disclosure.

The method 200 firstly comprises a step 202 of providing a heel pad 122and a sock having an outer surface 116 and an inner surface 118comprising a heel counter area 124. In the embodiment shown, the step202 of providing the heel pad 122 comprises a step of forming the heelpad 122, for instance and without being limitative by at least partiallymolding it, for instance with a mold assembly 300 as represented inFIGS. 9 and 10. The mold assembly 300 comprises, in the embodimentshown, a lower mold 310 in which two heel pad-forming cavities 320 areformed, and an upper mold 330. As represented in FIG. 10, in which themold assembly 300 is configured into an open configuration, depressionsand protrusions are formed in the heel pad-forming cavities 320 thatsubstantially correspond to the shape of the depressions, pads andabutting portions of the heel pads 122 to be formed.

The mold assembly 300 is also configurable into a closed configuration,as represented in FIG. 6, in which one or more materials, such as latexor any other resilient material, can be injected, to form a heel pad 122in each of the heel pad-forming cavities 320. Then the mold assembly 300is configured into the open configuration to remove the formed heel pads122 from the heel pad cavities 320. The method might further comprise astep of arranging additional layers, for instance at least partiallymade of tissue, in the mold assembly 300, so as to form inner and/orouter layers of the heel pads 122.

The method 200 then comprises a step 204 of securing the heel pad 122 tothe inner surface 118 of the sock 114, in the heel counter area 124thereof. In some embodiments, the method 200 comprises sewing the heelpad 122 to the sock 114, to the inner surface 118 thereof. In some otherembodiments, the heel pad 122 is glued to the inner surface 118 of thesock 114, stitched or secured by a combination of different techniquesso as to be permanently (i.e. irremovably) secured to the inner surface118 of the sock 114. It is understood that it is not necessary that anentirety of an outer surface 132 of the heel pad 122 be secured to theinner surface 118 of the sock 114.

The method 200 then comprises a step 206 of providing a footwear last400, as represented in FIG. 11, having an outer surface 402 with a heelpad-receiving recess 410 formed therein, for instance in a heel counterarea 404 thereof. The method 200 further comprises a step 208 ofpositioning the sock 118 over the footwear last 400 with the heel pad122 being at least partially received in the heel pad-receiving recess410 of the footwear last 400. In other words, the heel pad 122 issandwiched between the footwear last 400 and the inner surface 118 ofthe sock 114. It is understood that the footwear last 400 is dimensionedso that the sock 114 is fitted on the footwear last 400 and that theheel pad-receiving recess is dimensioned for the heel pad 122 to bestably received therein.

The method 200 then comprises a step 210 of covering at least partiallythe outer surface 116 of the sock 114 with a vulcanizable material (suchas, for instance, polyurethane, rubber or any other moldablevulcanizable material which a skilled addressee would consider to beappropriate). The method 200 then comprises a step 212 of forming afootwear upper 104 of the item of sock-lined footwear 100 with thevulcanizable material. In the embodiment shown, the step 212 comprisesbonding the vulcanizable material to the outer surface 116 of the sock114.

In an embodiment, the step 210 of covering at least partially the outersurface 116 of the sock 114 comprises superposing at least a layer ofthe vulcanizable material onto the outer surface 116 of the sock 114.The step 212 of forming the upper 104 comprises vulcanizing thevulcanizable material so as to bond to the outer surface 116 of the sock114 and to form the upper 104 of the item of sock-lined footwear 100.

In another embodiment, the step 210 could comprise a step of providingan outer mold and positioning the outer mold over the sock 114positioned over the footwear last 400 to enclose the sock 110 betweenthe outer mold and the footwear last 400. The outer mold could bedimensioned so that a space is formed between an inner surface of theouter mold and the outer surface 116 of the sock 114. The dimensions ofthis space depend on the final dimensions of the item of sock-linedfootwear 100. The method 200 could further comprise injecting thevulcanizable material between the outer surface 116 of the sock 114 andthe inner surface of the outer mold and vulcanizing the vulcanizablematerial so as to bond to the outer surface 116 of the sock 114 and toform the upper 104 of the item of sock-lined footwear 100.

Once the vulcanizable material is vulcanized, the outer layer 120 formedby the vulcanized material and the sock 114 are secured to each other soas to form the item of sock-lined footwear 100.

The manufacturing method 200 might further comprise a step of providingan outsole 102 and securing (for instance gluing or using any othersuitable mechanical fastener) the outsole 102 to the upper 104.

It is understood that the present invention is not limited to the abovedescribed embodiments. Several alternative embodiments and examples havebeen described and illustrated herein. The embodiments of the inventiondescribed above are intended to be exemplary only. A person of ordinaryskill in the art would appreciate the features of the individualembodiments, and the possible combinations and variations of thecomponents. A person of ordinary skill in the art would furtherappreciate that any of the embodiments could be provided in anycombination with the other embodiments disclosed herein. It isunderstood that the invention may be embodied in other specific formswithout departing from the central characteristics thereof. The presentexamples and embodiments, therefore, are to be considered in allrespects as illustrative and not restrictive, and the invention is notto be limited to the details given herein. Accordingly, while thespecific embodiments have been illustrated and described, numerousmodifications come to mind. The scope of the invention is thereforeintended to be limited by the scope of the appended claims.

1. A sock-lined footwear upper defining a foot-receiving cavity andcomprising: a sock having an outer surface and an inner surface at leastpartially delimiting the foot-receiving cavity and comprising a heelcounter area; an outer layer covering at least partially the outersurface of the sock; and a heel pad at least partially secured to theinner surface of the sock in the heel counter area thereof.
 2. Thesock-lined footwear upper according to claim 1, wherein the heel pad hasa sole-facing edge, a length, a height, an inner surface at leastpartially delimiting the foot-receiving cavity and an opposed outersurface at least partially secured to the inner surface of the sock, andwherein the heel pad comprises at least one heel-abutting portionprotruding inwardly and extending along at least a portion of the lengthof the heel pad, in an upper portion thereof, the heel-abutting portioncreating a thickness variation in the heel pad and being shaped anddimensioned to extend at least partially above a heel of a user's footat least partially engaged into the foot-receiving cavity.
 3. Thesock-lined footwear upper according to claim 2, wherein said at leastone heel-abutting portion comprises one or more elongated cushioningpads protruding inwardly and comprising a peripheral border at leastpartially rounded.
 4. The sock-lined footwear upper according to claim2, wherein said at least one heel-abutting portion comprises twoelongated cushioning pads, and wherein the heel pad has an axis ofsymmetry extending substantially vertically between said two elongatedcushioning pads.
 5. The sock-lined footwear upper according to claim 2,wherein the heel pad comprises one or more depressions formed in theinner surface and creating an additional thickness variation in the heelpad, and wherein, considered along the height of the heel pad, said oneor more depressions comprises an elongated depression extending belowsaid at least one heel-abutting portion.
 6. The sock-lined footwearupper according to claim 5, wherein the elongated depression has upperand lower edges, and wherein a distance between the upper edge and thesole-facing edge of the heel pad varies along the length of the heelpad.
 7. The sock-lined footwear upper according to claim 5, wherein saidone or more depressions further comprises a substantially circularcentral depression having an increasing depth towards a center thereof.8. The sock-lined footwear upper according to claim 7, wherein theelongated depression at least partially intersects the centraldepression.
 9. The sock-lined footwear upper according to claim 2,wherein, considered along the height of the heel pad, the heel pad has amiddle portion extending below the upper portion comprising the at leastone heel-abutting portion, and, considered along at least a portion ofthe length of the heel pad, a thickness of the upper portion is greaterthan a thickness of the middle portion.
 10. The sock-lined footwearupper according to claim 9, wherein the heel pad further comprises asole-adjacent portion, wherein, considered along the height of the heelpad, the middle portion extends between the upper portion and thesole-adjacent portion, and wherein, considered along at least a portionof the length of the heel pad, a thickness of the sole-adjacent portionis smaller than the thickness of the middle portion.
 11. The sock-linedfootwear upper according to claim 1, wherein the heel pad comprises aperiphery sewed at least partially to the inner surface of the sock. 12.The sock-lined footwear upper according to claim 1, wherein the heel padcomprises an inner layer, an outer layer and a resilient material layerat least partially made of latex sandwiched between the inner and outerlayers.
 13. A heel pad for a sock-lined footwear upper comprising aninner sock having an inner surface at least partially delimiting afoot-receiving cavity and comprising a heel counter area, the heel padhaving a length and a height and comprising: an outer surface securableto the inner surface of the inner sock in the heel counter area thereof;an opposed inner surface; and at least one heel-abutting portionprotruding forwardly and creating at least one protrusion on the innersurface, the at least one heel-abutting portion extending along at leasta portion of the length and being shaped and dimensioned to extend atleast partially above a heel of a user's foot at least partially engagedinto the foot-receiving cavity when the heel pad is at least partiallysecured to the inner sock.
 14. The heel pad according to claim 13,wherein the heel pad has a substantially semi-circular shape having anapex and being delimitated by an arcuate peripheral edge and asubstantially straight peripheral edge, said at least one heel-abuttingportion comprising two elongated cushioning pads extending adjacent tothe arcuate peripheral edge and defining a convexity towards the apex,and wherein the heel pad has an axis of symmetry extending substantiallyvertically between said two elongated cushioning pads.
 15. The heel padaccording to claim 14, further comprising an elongated depression formedin the inner surface and extending, considered along the height of theheel pad, below said two elongated cushioning pads.
 16. The heel padaccording to claim 15, further comprising a substantially circularcentral depression formed in the inner surface, the elongated depressionat least partially intersecting the central depression.
 17. An item ofsock-lined footwear comprising: an outsole having an inner surface andan outer surface; and a sock-lined footwear upper according to claim 1,the sock-lined footwear upper extending from the outsole, the heel padbeing adjacent to the outsole.
 18. The item of sock-lined footwearaccording to claim 17, wherein the heel pad is adjacent to the outsole.19. A method for manufacturing an item of sock-lined footwear, themethod comprising: providing a heel pad and a sock having an outersurface and an inner surface comprising a heel counter area; securingthe heel pad to the inner surface of the sock, in the heel counter areathereof; providing a footwear last having an outer surface with a heelpad-receiving recess formed therein; positioning the sock over thefootwear last with the heel pad at least partially received in the heelpad-receiving recess; covering at least partially the outer surface ofthe sock with a vulcanizable material; and forming at least partially anupper of the item of sock-lined footwear with said vulcanizablematerial.
 20. The method according to claim 19, wherein securing theheel pad to the inner surface of the sock further comprises sewing theheel pad to the inner surface of the sock.